PROCESS FOR PRODUCING A COATED FOOD PRODUCT

Abstract: A process for manufacturing a food product having a thick and irregular coating comprising: (a) coating the food product with a batter; and (b) coating the food product with agglomerated powder; such that the ratio of batter to agglomerated powder is 2.5:1 to 1:1.5.

Description: PROCESS FOR PRODUCING A COATED FOOD PRODUCT FIELD OF THE INVENTION The invention relates to a process for manufacturing a food product having a thick and irregular coating. BACKGROUND AND PRIOR ART Food products having a thick, irregular coating have been popular with consumers for some time. Currently such products are provided by a number of processes: One of these processes comprises initially coating the food product with a thick layer of a viscous batter [having a flow time of >60 seconds through a flow cup number 6 BS3900 A6 (Stanhope Seta)], then applying a thin powder coating before pre-frying, such that the typical ratio of batter to powder is 3:1. This process has the disadvantage that it is very messy, transfer conveyors and the oil used for pre-frying becoming quickly contaminated with the batter and powder, requiring frequent shut downs for cleaning. Furthermore, this process is difficult to control and results in significant coating weight variations. Another process comprises initially coating the food product with a thin layer of a conventional batter (having a low viscosity ie a flow time of approximately 10 seconds through a flow cup number 6 BS3900 A6) followed by a powder coating application, this process is then repeated one or more times before pre-frying. This second process minimises the problems of the first, however it is more complex and therefore costly. Furthermore, this process may result in a product having a different coating appearance. We have now solved the above-mentioned problems of the prior art processes by agglomeration of the powder coating prior to its application to the product. SUMMARY OF THE INVENTION Accordingly the invention provides a novel process for coating a food product with a powder to produce a thick irregular coating comprising: (a) coating the food product with a batter; and (b) coating the food product with agglomerated powder; such that ratio of batter : agglomerated powder is 2.5:1 to 1:1.5. Furthermore the invention provides a coated food product manufactured according to the defined novel process. DEFINITION OF THE INVENTION Preferably the ratio of batter to agglomerated powder is 2:1 to 1:1, most preferably 1:1. Once the food product has been coated, the coating is preferably pre-set, for example by pre-frying, and the food product is then stored for consumption, typically by freezing. Suitable food products may be selected from meat, poultry, vegetables and fish. The powder composition may comprise any suitable ingredient as will be readily determined by the skilled man in the art. For example the powder may comprise flour, such as wheat flour, maize flour and mixtures thereof; starch; spray dried fats, such as spray dried hydrogenated vegetable fats; other fats and/or fat replacers; proteins,- flavouring agents, such as salt, sugar, onion powder, garlic powder; spices; rusk; or flavour enhancers. The batter composition may comprise any suitable ingredient as will be readily determined by the skilled man in the art. For example the batter may comprise flour, such as wheat flour, maize flour and mixtures thereof; starch; spray dried fats, such as spray dried hydrogenated vegetable fats; flavouring agents, such as salt, sugar, onion powder, garlic powder; spices; rusk; raising agents; or processing aids. Any suitable viscosity of batter may be used providing that the final ratio of batter to powder lies within the defined limits, however, for ease of processing, the batter preferably has a viscosity such that the flow rate through a flow cup number 6 BS3900 A6 is from 10 to 60 seconds. The food product may optionally be initially predusted prior to the provision of the batter. The pre-dust composition may comprise any suitable ingredient as will be readily determined by the skilled man in the art. For example, the pre-dust may comprise flour, such as rice flour, spray dried fats, such as spray dried hydrogenated vegetable fats; flavouring agents,- starch; rusk; or emulsifiers. The Agglomeration Process Agglomeration is a well known technique whereby ingredients are bound together under the influence of material bridges or pressure in such a way that a stable granule is formed. There are a number of different suitable agglomeration processes. Two such examples are: (i) a fluidised bed agglomerator. Water is sprayed onto the fluidised powder within a hot air environment and particles are built up. Once all the water has been sprayed on, the excess moisture is removed by further hot air fluidisation. (ii) Pressure agglomeration, for example roller compacter (Alexander Machine) . The powder is fed between 2 rollers which apply pressure at up to 100 bar. Heat is generated by the mechanical work of the rollers which causes the hydrogenated vegetable fat content of the powder to melt enabling the powder to aggregate. The agglomerates are then sieved into the desired size fractions. Examples A comparative trial was carried out between a traditional process and the process of the invention using a process line comprising a plate moulder (Formax model 19) to shape meat patties weighing 67 grammes each, a dip enrober (Stein model APB) for batter application, a breader applicator machine (Stein model XLF) and a continuous oil frier heated at 190°C. Similar ingredients were used in both trials: (a) Batter dries formulation: Wheat flour 80% Hydrogenated vegetable fat 4.5% Modified starch 3% Raising agent 0.5% Flavours and spices 12% (b) Powder formulation: Wheat flour 60% Spray dried hydrogenated vegetable fat 20% Rusk 2% Flavours and spices 10% Flavour enhancer 8% Conventional process In the conventional process, the batter enrober plant was filled with batter made from batter dries (a) mixed with water to give a flow cup viscosity of 75 seconds (Cup No 6, BS 3900 A6, Stanhope Seta) . The breader applicator plant was filled with powder (b) . Meat patties were subjected to the successive steps of the continuous coating and setting process in a trial which lasted a total of 100 minutes. Results are described in the following table. Process of the invention In the process of the invention, the batter enrober plant was filled with batter made from batter dries (a) mixed with water to give a flow cup viscosity of 22 seconds (Cup No 6, BS 3900 A6, Stanhope Seta) . The breader applicator plant was filled with powder (b) agglomerated on a roller compactor granulator (Alexanderwerke model WP50/N75) at 75 Bar nip pressure and granulated through a 3mm mesh screen. Meat patties were subjected to the successive steps of the continuous coating and setting process in a trial which lasted a total of 180 minutes. Results are described in the following table. Results Conventional Invention process processing route route Meat patty weight 67 g 67 g Battered patty 90.5 g 84 g weight Fully coated 101 g ± 8.75 g 99.75 g ± 2.3 g uncooked product SD=4.9 SD=1.9 weight Product surface Highly variable Regularly rugged characteristics appearance surface. ranging from smooth to highly rugged. Processing Intensive line Low line soilage. observations soilage. Significant Low debris in debris build up frying oil. in frying oil. Process Process interrupted after voluntarily 100 min for interrupted after required 180 min. cleaning. Eating characteristics of products made by either route after frying were similar. It can clearly be seen that the route of the invention offers significant product and processing advantages over the conventional processing route.

Claims: CLAIMS 1. A process for coating a food product with a powder to produce a thick and irregular coating comprising: (a) coating the food product with a batter; and (b) coating the food product with agglomerated powder; such that the ratio of batter to agglomerated powder is 2.5:1 to 1:1.5. 2. A process according to claim 1 wherein the ratio of batter : agglomerated powder is 2:1 to 1:1. 3. A process according to claim 1 or 2 wherein the ratio of batter : agglomerated powder is 1:1. 4. A process according to any preceding claim wherein the food product is initially pre-dusted prior to provision of the batter. 5. A process according to any preceding claim wherein the food product is selected from fish, vegetable, meat and poultry products.

Inventors: JARRETT GRAHAM ANDREW, MCBRIDE MALCOLM JOHN, SYMIEN SERGE ALFRED, WALKER PETER, WOOTEN ALAN, JARRETT, GRAHAM, ANDREW, MCBRIDE, MALCOLM, JOHN, SYMIEN, SERGE, ALFRED, WALKER, PETER, WOOTEN, ALAN
Applicants: UNILEVER NV, UNILEVER PLC, UNILEVER N.V.
Application year: 1994
Main classification: A23P1
IPC codes: A23L1, A23P1